Remotely controlled packable robot

ABSTRACT

A remotely controlled packable robot features a chassis, right and left main tracks for maneuvering the chassis, and right and left tracked rotatable flipper arms for maneuvering the chassis. An integrated drive assembly is provided for each main track and flipper pair and includes a motor in a housing attached to the chassis for rotating the flipper and a stator and rotor disposed about the motor housing for driving the main track and the flipper track.

RELATED APPLICATIONS

This application claims benefit of and priority to U.S. Provisional Application Ser. No. 62/397,055 filed Sep. 20, 2016, under 35 U.S.C. §§ 119, 120, 363, 365, and 37 C.F.R. § 1.55 and § 1.78, which is incorporated herein by this reference.

FIELD OF THE INVENTION

This subject invention relates to remotely controlled maneuverable ground robots.

BACKGROUND OF THE INVENTION

Several existing ground robots are fairly maneuverable but are fairly heavy and too large to fit in a soldiers backpack. See, for example, U.S. Pat. Nos. 8,201,649; 5,022,812 and 7,597,162 incorporated herein by this reference. Other robots are smaller in weight and can be placed in a backpack but are not maneuverable enough, for example, to climb stairs. See U.S. Pat. No. 9,180,920 and published U.S. Patent Application No. 2009/0266628 incorporated herein by this reference.

BRIEF SUMMARY OF THE INVENTION

Featured is a lightweight, compact, man packable robot which in one example is highly mobile, unmanned, and can include advanced sensors and mission modules for dismounted forces. In one example, the ground robot is particularly useful for clearing buildings, caves, and other restricted terrain where close quarters combat is likely.

Featured is a remotely controlled packable robot comprising a chassis with a top surface and a bottom surface. A pair of main tracks are for maneuvering the chassis. There is an open channel under the robot defined by the bottom surface of the chassis and the main tracks. A robot arm is foldable from a stored position in the open channel underneath the robot chassis to a deployed position extending upwards from the top surface of the chassis. A camera assembly is also foldable from a stowed position in the open channel underneath the robot chassis next to the robot arm to a deployed position extending upwards from the top surface of the chassis. A skid plate may be provided for each main track.

In one example, a foldable base member for the robot arm is located on one end of the chassis and a foldable base member for the camera assembly is located on an opposite end of the chassis.

Also featured is a remotely controlled packable robot comprising a chassis, right and left main tracks for maneuvering the chassis, and right and left rearward tracked rotatable flipper arms for maneuvering the chassis. An integrated concentric drive assembly for each main track and flipper pair rotates a flipper, drives a main track, and drives the flipper track. A motor in a housing rotates the flipper. The right and left flippers arms can be independently driven. A stator and rotor disposed about the housing drives the main track and the flipper track. The housing is coupled to the chassis.

In one example, a slip clutch is attached to the flipper arm and is driven by the motor via a gear train. The stator may be affixed about the housing and preferably includes teeth with windings thereabout. The rotor preferably rotates about the housing and includes magnets therein. The rotor may include exterior teeth driving the main track. A sprocket may be attached to the rotor to drive the flipper track.

The subject invention, however, in other embodiments, need not achieve all these objectives and the claims hereof should not be limited to structures or methods capable of achieving these objectives.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Other objects, features and advantages will occur to those skilled in the art from the following description of a preferred embodiment and the accompanying drawings, in which:

FIG. 1 is schematic view of an example of a remotely controlled packable ground robot in accordance with an example of the invention;

FIG. 2 is a schematic rear view of the robot shown in FIG. 1;

FIG. 3 is a schematic view showing the robot with its arm and camera assembly in their stowed position;

FIG. 4 is a schematic view of the robot showing the camera assembly and the robot arm being deployed;

FIG. 5 is a schematic view showing the robot with the camera assembly and robot arm fully deployed;

FIG. 6 is a another schematic view showing an example of the robot inverted with the camera assembly and robot arm in their stowed position in the underside of the robot;

FIG. 7 is another schematic view showing the robot with the camera assembly and the robot arm deployed;

FIG. 8 is a schematic cross sectional view showing and example of a compact motor assembly in accordance with aspects of the invention;

FIG. 9 is an exploded view of the drive motor;

FIG. 10 is another view of the motor;

FIG. 11 is a schematic view showing an example of robot track side pods;

FIG. 12 is a schematic top view showing an example of the chassis component layout;

FIGS. 13-16 are schematic views showing various configuration options for a robot in accordance with examples of the invention; and

FIGS. 17-29 are views of another embodiment of one example of the robot.

DETAILED DESCRIPTION OF THE INVENTION

Aside from the preferred embodiment or embodiments disclosed below, this invention is capable of other embodiments and of being practiced or being carried out in various ways. Thus, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. If only one embodiment is described herein, the claims hereof are not to be limited to that embodiment. Moreover, the claims hereof are not to be read restrictively unless there is clear and convincing evidence manifesting a certain exclusion, restriction, or disclaimer.

FIG. 1 shows an example of a remotely controlled packable robot 10 including a chassis 12. Right 14 a and left 14 b main tracks maneuver the chassis as do optional right 16 a and left 16 b rearward rotatable tracked flipper arms. Robot arm 18 with end effector 19 and/or camera assembly 20 may also be included.

As shown in FIG. 2, chassis 12 is thin and plate-like in construction and includes top surface 22 and bottom surface 24 disposed high (e.g., three inches) above the ground for clearance over obstacles.

In this way, an open channel 26 under the robot is defined by the bottom surface 24 of the chassis 12 and between the main tracks 14 a and 14 b. For transport in a backpack by a dismounted soldier or user, both the robot arm 18 and the camera assembly 20 are folded underneath the robot chassis and reside almost completely in channel 26 as shown in FIG. 3.

In one preferred design, robot arm 18 is mounted onto the top of foldable base plate member 30, FIG. 4 rotatably coupled to the rear end of the chassis. In FIG. 5, the bottom of base plate member 30 is on the top of the chassis and the base plate member can be releasably secured to the top 22 of chassis 12 using, for example, a latch on chassis 12. Arm 18 is now in the deployed position extending upwards from the top surface of the chassis. In FIGS. 3 and 6, the arm base member 30 is folded relative to the chassis to a position depending downward from the chassis and the arm is stowed in the open channel under the robot next to the camera assembly.

Foldable base member plate 32 for the camera assembly 20 is rotatably coupled to the forward end of the chassis. The camera assembly 20 is coupled onto the top of this base member 32 and thus can be stowed as shown in FIGS. 3 and 6 in the open channel underneath the robot adjacent the robot arm and then deployed as shown in FIGS. 4 and 5 so camera assembly 20 extends upward from the top surface of the chassis. In FIG. 5, a latch can be used to releasably lock the bottom of camera assembly base member 32 into engagement with the top of the chassis. The robot arm and camera assembly can be manually stowed, deployed, and latched. Preferably, the base member plates 30, 32 rotate from a position where they lie on the top surface of the chassis to a position where they depend downward from an edge of the chassis (e.g., at a right angle to the plane of the chassis).

Preferably, the robot is approximately 4 inches tall and 13 inches wide and 16 long with the arm and camera assembly in the stowed position and with the flipper arms also stowed as shown in FIG. 6. In the deployed position shown in FIG. 7, the arm extends approximately 30 inches and the flippers when extended make the robot approximately 25 inches long enabling maneuverability over obstacles and, for example, up and down stairs.

Motors in the robot arm 18, FIG. 5 rotate shoulder 40 and elbow 42, rotate wrist 44 and open and close end effector 19 jaw 46. See also U.S. Pat. No. 8,176,808 incorporated herein by this reference. Camera assembly 20 may include motors to rotate and tilt the camera head 21 relative to base member 32. Camera head 20 may include a zoomable color camera as well as other imaging technology (e.g., infrared cameras, and the like).

Preferably, when the flippers are incorporated, so too is an integrated concentric drive assembly 49 for each main track and flipper pair as shown in FIGS. 8-10. One such assembly, for example, would be mounted to the chassis to drive right track 14 a, rotate right rear flipper 16 a, and drive its track 17 a. Another such assembly would be mounted to the chassis and used to drive left track 14 b, rotate left rear flipper 16 b and drive its track 17 b.

Preferably electric motor 50 is disposed inside motor housing 52 (coupled to the chassis) and rotates a flipper arm 16 via planetary gear box 54 and slip clutch 56 which is fixed to flipper arm 16. Slip clutch 56 prevents damage to the flipper arm if the robot is dropped. Encoder 57 enables the absolute location of the flipper arm to be known. Stator 60 and rotor 62 are disposed about motor housing 52 for driving a main track 14 and the flipper track 17 via sprocket 64. Stator 60 and rotor 62 are concentric with motor 50 housing 52. In one design, stator ring 60 is a fixed about the housing 52 and includes teeth 70 each with a winding 72 thereabout. Rotor ring 62 can rotate about motor housing 52 via bearings 74 a and 74 b. Rotor 62 includes therein, inside the ring can, permanent magnets 80. Battery power is used to energize motor 50 and windings 72.

A main track 14 is disposed about rotor 62. Sprocket 64 has a flipper track 17 disposed about it. Sprocket 64 is coupled to rotor 62. In this way, rotation of the rotor rotates both a flipper track and a main track. Rotor 62 may include exterior teeth 78 for driving a main track.

FIG. 11 shows two batteries 100 a and 100 b in a side pod disposed within a main track 14. Electronic speed controllers 101 can also be located in the side pod. This battery location provides a lower center of gravity for the robot and the batteries are hot swappable through a hinged door. Alternatively, a battery cage assembly slides into the sidepod. A track tensioning mechanism 102 is also shown.

FIG. 12 shows an example of a chassis component layout including a radio 104 for remotely communicating with the robot and for transmitting video signals back to an operator control unit from the camera assembly. Various other cameras 150, printed circuit boards, and processor and controller boards 160 a-160 c are also shown. Pixhawk 160 a-160 c are also shown. Pixhawk (real-time controller with integrated inertial measurement unit), Ethernet switch, and Nitrogen (embedded Linux board) boards may be used. An example of an operator control unit is shown in U.S. Pat. No. 9,014,874 incorporated herein by this reference. In some embodiments, an operator control unit may include a hardened military style tablet device.

FIGS. 13-16 show various configuration options for the robot. In FIG. 13, the camera and arm are stowed underneath the robot chassis and the flippers 16 a, 16 b are rotated to be adjacent main tracks 14 a, 14 b for storage and transport of the robot. In FIG. 14, the camera assembly 20 and robot arm 18 are deployed and the flippers 14 a, 14 b are rotated into position to lift the forward end of the robot to initiate stair climbing or to surmount a large obstacle. FIG. 15 shows the flippers 16 a, 16 b rotated straight behind the robot for stabilizing the robot during climbing stairs. FIG. 16 shows the position of the flipper arms for normal operation.

Preferably, the weight of the combined system is less than 32 pounds with the operator control unit weighting less than 5 pounds. In the folded configuration, the robot fits in a tactical or assault backpack (MOLLE brand or others) which is approximately 16 inches high, 13 inches wide, and 4 inches thick. In one example, the MOLLE Assault Pack II NSN number is: 8465-01-580-0981. The robot can climb and descend 8.5 inch by 10 inch stairs, is self righting, and has a very low center of gravity. At the same time, the robot has a fairly high ground clearance.

In one example, motor 50 is an EC 32 Flat (339268) motor and 531:1 and gear box 54 is a 531:1 32C Planetary Gear Head available from Maxon Precision Motors, Inc. The chassis and side pods may be made of aluminum, the tracks can be made of polyurethane, and the flippers may be made of carbon fiber. The arm may be 4 pounds total weight, have a maximum reach of 26 inches and 5 pound lift capability at full extension. Preferably, non-back drivable gear boxes with slip clutches are used in the arm. The chassis may include cameras on the front, rear, and/or sides, for example, video and/or thermal cameras. The camera assembly may be equipped with a video camera, have a 360° continuous pan range, clockwise and counter clockwise rotation and a tilt range of −45° to +90°. Illumination sources, thermal cameras, and the like can also be equipped with the camera assembly.

FIGS. 17-27 show another embodiment of the robot where the base member 32 for the camera assembly includes a rotatable arm to which the camera assembly is attached. In this embodiment, the chassis also includes a U-shaped cut-out at the rear end thereof defining two spaced arms. The base member plate for the robot arm is located in the cut-out and is hinged between the two chassis arms and flips upside down relative to the chassis to store the aim underneath the robot. FIGS. 17-27 also show various latch mechanisms for retaining the robot arm and the camera assembly in their deployed positions on the top of the chassis.

A spring loader slider 120, FIGS. 19-20 on member 32 can be used in connection with latch 122 on chassis 12 to releasably lock member 32 on top of chassis 12. Member 32 pivots about hinge 124 when released.

FIGS. 21-22 show member 30′ to which the robot arm is attached. Member 30′ resides in U-shape cut-out 130 in the end of chassis 12 and pivots about hinges 132 a and 132 b. Latch 134 may be used to secure folding base member 30′ into the deployed position shown in FIG. 21 when latch bar 136 under chassis 12 rotates or otherwise is driven into slot 138 in the sidewall of member 30′. When the latch bar 136 is clear of slot 138 as shown in FIG. 23, member 30′ can be rotated to store the robot arm under the chassis as shown in FIG. 24. See also FIGS. 24-27 which show spring loaded antennas 140 a and 140 b foldable relative to chassis 12 into sidewalls thereon.

FIG. 28 shows skid plate 162 located between the sidepod 164 and the main track 14 and attached to the sidepod. The skid plate may be composed of a low friction plastic, preferably PTFE. The plate is thick enough so that the weight of the robot is born by the sidepod via the skid plate when the robot is on level ground. This configuration promotes quiet operation on flat ground. The skid plate extends beyond the sidepod, nearly touching both rotor 62 and guide roller 166. The extended length of the skid plate provides additional support of the track during stairclimbing, facilitating the motion of the robot on stairs. FIG. 29 shows independent movement of flippers 16 a and 16 b. The flippers may be controlled independently to facilitate maneuvering on uneven terrain.

Although specific features of the invention are shown in some drawings and not in others, this is for convenience only as each feature may be combined with any or all of the other features in accordance with the invention. The words “including”, “comprising”, “having”, and “with” as used herein are to be interpreted broadly and comprehensively and are not limited to any physical interconnection. Moreover, any embodiments disclosed in the subject application are not to be taken as the only possible embodiments. Other embodiments will occur to those skilled in the art and are within the following claims.

In addition, any amendment presented during the prosecution of the patent application for this patent is not a disclaimer of any claim element presented in the application as filed: those skilled in the art cannot reasonably be expected to draft a claim that would literally encompass all possible equivalents, many equivalents will be unforeseeable at the time of the amendment and are beyond a fair interpretation of what is to be surrendered (if anything), the rationale underlying the amendment may bear no more than a tangential relation to many equivalents, and/or there are many other reasons the applicant can not be expected to describe certain insubstantial substitutes for any claim element amended. 

What is claimed is:
 1. A remotely controlled robot comprising: a chassis; right and left main tracks for maneuvering the chassis; right and left tracked rotatable flipper arms for maneuvering the chassis; and an integrated drive assembly for each main track and flipper pair including: a motor in a housing attached to the chassis for rotating the flipper, a stator and rotor disposed about the motor housing for driving the main track and the flipper track, and each rotor including exterior teeth driving a respective main track.
 2. The robot of claim 1 in which each integrated drive assembly further includes a slip clutch attached to a respective flipper arm and driven by a respective motor via a gear train.
 3. The robot of claim 1 in which each stator is affixed about a respective housing and includes teeth with windings thereabout.
 4. The robot of claim 1 in which each rotor rotates about a respective housing and includes magnets therein.
 5. The robot of claim 1 further including a sprocket attached to each rotor driving a flipper track.
 6. The robot of claim 1 in which the chassis has a top surface and a bottom surface and there is an open channel under the robot defined by the bottom surface of the chassis and the main tracks.
 7. The robot of claim 6 further including a robot arm foldable from a stored position in said open channel underneath the robot chassis to a deployed position extending upwards from the top surface of the chassis.
 8. The robot of claim 7 including a foldable base member for the robot arm located on one end of the chassis.
 9. The robot of claim 8 in which the foldable base member for the robot arm includes a member hinged to the chassis.
 10. The robot of claim 9 further including a latch mechanism for releasably retaining the foldable base member in the deployed position.
 11. The robot of claim 8 in which the chassis includes a U-shaped cut-out therein and the foldable base member resides in the cut-out.
 12. The robot of claim 6 further including a camera head foldable from a stowed position in said open channel underneath the robot chassis to a deployed position extending upwards from the top surface of the chassis.
 13. The robot of claim 12 including a foldable base member for the camera head located on one end of the chassis.
 14. The robot of claim 12 further including a latch mechanism for releasably retaining the camera head in the deployed position.
 15. A remotely controlled robot comprising: a chassis; right and left main tracks for maneuvering the chassis; right and left rotatable flipper arms for maneuvering the chassis; and an integrated drive assembly for each main track and flipper arm pair including: a motor in a housing attached to the chassis for rotating the flipper arm, a stator and rotor disposed about the motor housing for driving the main track, and each rotor including exterior teeth driving a respective main track.
 16. The robot of claim 15 in which each integrated drive assembly further includes a slip clutch attached to a respective flipper arm and driven by a respective motor via a gear train.
 17. The robot of claim 15 in which each stator is affixed about a respective housing and includes teeth with windings thereabout.
 18. The robot of claim 15 in which each rotor rotates about a respective housing and includes magnets therein.
 19. The robot of claim 15 in which each flipper arm includes a track and the robot further including a sprocket attached to each respective rotor driving a respective flipper track.
 20. The robot of claim 15 in which the chassis has a top surface and a bottom surface and there is an open channel under the robot defined by the bottom surface of the chassis and the main tracks.
 21. The robot of claim 20 further including a robot arm foldable from a stored position in said open channel underneath the robot chassis to a deployed position extending upwards from the top surface of the chassis.
 22. The robot of claim 20 further including a camera head foldable from a stowed position in said open channel underneath the robot chassis to a deployed position extending upwards from the top surface of the chassis.
 23. A remotely controlled robot comprising: a chassis; at least one main track for maneuvering the chassis; at least one rotatable flipper arm for maneuvering the chassis; and an integrated drive assembly for the main track and the flipper arm and including: a motor in a housing attached to the chassis for rotating the flipper arm, a stator and rotor disposed about the motor housing for driving a main track, and each rotor including exterior teeth for driving a respective main track.
 24. The robot of claim 23 in which the integrated drive assembly further includes a slip clutch attached to the flipper arm and driven by the motor via a gear train.
 25. The robot of claim 23 in which the stator is affixed about the housing and includes teeth with windings thereabout.
 26. The robot of claim 23 in which the rotor rotates about the housing and includes magnets therein.
 27. The robot of claim 23 in which the flipper arm includes a track and the robot further including a sprocket attached to the rotor driving the flipper track.
 28. A remotely controlled robot comprising: a chassis with a top surface and a bottom surface and an open channel under the robot defined by the bottom surface of the chassis and the main tracks; right and left main chassis tracks; right and left tracked rotatable flipper arms for maneuvering the chassis; an integrated drive assembly for each main track and flipper pair including: a motor in a housing attached to the chassis for rotating the flipper, a stator and rotor disposed about the motor housing for driving the main chassis track and the flipper track; a robot arm foldable from a stored position in said open channel underneath the robot chassis to a deployed position extending upward from the top surface of the chasses; and a foldable base member for the robot arm located on one end of the chassis.
 29. The robot of claim 28 in which each integrated drive assembly further includes a slip clutch attached to a respective flipper arm and driven by a respective motor via a gear train.
 30. The robot of claim 28 in which each stator is affixed about a respective housing and includes teeth with windings thereabout.
 31. The robot of claim 28 in which each rotor rotates about a respective housing and includes magnets therein.
 32. The robot of claim 28 in which each rotor includes exterior teeth driving a respective main track.
 33. The robot of claim 28 further including a sprocket attached to each rotor driving a flipper track.
 34. The robot of claim 28 further including a camera head foldable from a stowed position in said open channel underneath the robot chassis to a deployed position extending upwards from the top surface of the chassis.
 35. The robot of claim 34 including a foldable base member for the camera head located on one end of the chassis.
 36. The robot of claim 35 further including a latch mechanism for releasably retaining the camera head in the deployed position.
 37. The robot of claim 28 in which the foldable base member for the robot arm includes a member hinged to the chassis.
 38. The robot of claim 28 further including a latch mechanism for releasably retaining the foldable base member in the deployed position.
 39. The robot of claim 28 in which the chassis includes a U-shaped cut-out therein and the foldable base member resides in the cut-out. 